New generation of automotive components manufactured in a high performance simo alloy.

This project aims at developing the manufacturing technology of new simo alloys with higher corrosion resistant and mechanical properties at competitive prices. Activities will be focused in integrating technologies in different manufacturing systems supported by sample and prototypes manufacturing.

Industry is nowadays facing new social challenges that imply its quick evolution to answer social and environmental aspects. Transport expectations in short and medium term are related to more sustainable vehicles consuming less energy and emitting fewer gases. This challenge can only be overcome by developing a new generation of materials that will allow managing high temperature exhaust gases with the final aim of: recovering a significant quantity of their energy content or by allowing hosting high temperature catalytic reactions to reduce exhaust gases emission. The most representative industrial sector related with transport responsible of the higher volume of green house effect gases emission is automotive. The significant pressure of authorities in terms of emissions reduction has led to the development of technologies link to the engine ancillary equipments with the aim of improving energy yield (turbo) and reduce gases emissions (EGR). Both technologies are supported in components that have to withstand high temperature strains, erosive and corrosive conditions. The alloys used in these applications have been focused on steel alloys, mainly high grade austenitic stainless steels (AISI 304L) or refractory steels. However significant cost limitations due to the use of scarce and high value elements within the alloy have tackle the development of a new generation of cast iron alloy SiMo. This alloy has significantly lower alloy content together with a higher thermal conductivity and lower expansion coefficient that render high performance up to 620ºC. The life of this alloy is clearly conditioned by its eutectoid transformation point and the above mentioned systems can´t evolve to higher yield engines that will require higher working temperatures and also support less periodical maintenance or equipments reposition. The addition of elements such as Chrome and Silicon are an alternative to increase the corrosion resistant and increase the eutectoid temperature allowing their use at higher temperatures and higher corrosive environments. However the effect of chemical elements is detrimental in many occasions conditioning graphite shape and shrinkage generation and requires special additions of other elements to counteract this deleterious situations. The main types of components manufactured in SiMo alloy are manifolds and turbine housings that are normally characterized by their dimensional complexity and low thicknesses. Thus flow ability, and lack of leaks are critical aspects that are clearly dependant on the material characteristics but also in the process design and performance. These types of components can be competitively manufactured in high volumes using green sand foundry process in differentiated vertical or in horizontal molds facilities. Both systems present particularities related to the design of the molds and can be used to manufacture different type of parts based on the bigger size potential of the horizontal process and higher production rate of the vertical system. However the high alloy content of these materials requires specific manufacturing strategies to introduce them into standard material materials manufacturing planning, avoiding contaminations with elements present in SiMo materials. The main objective of this project is to develop a new generation of manifolds and turbine housings based on a new alloy and a new manufacturing strategy to increase the scope for the application of these alloys up to 950ºC.. To achieve this main objective different specific technical objectives have been defined: • Development and validation of a new SiMo alloy with the modification of its chemical composition incorporating new elements (Cr) and increasing the content of already existing ones (Si). • Development of a new graphitization process with the addition of trace elements to counteract the effect of main alloying elements affecting the roundness of graphite. • New strategy to incorporate the manufacturing of highly alloyed materials in the manufacturing of non-alloyed standard materials. • Integration of new controls like creep in the evaluation process of these type of materials, to evaluate their feasibility to be used in other applications. Differente phases will be carried out to achieve before mentioned objectives: PHASE 1: TEST SAMPLES DESIGN IN TERMS OF SHAPE AND CHEMICAL COMPOSITION.PHASE 2: TEST SAMPLES MANUFACTURING AND PRELIMINARY PROCESS SETTING UP.PHASE 3: NEW ALLOY SELECTION.PHASE 4: PROTOTYPE DESIGN AND MANUFACTURING PROGRAM.PHASE 5: PROTOTYPE MANUFACTURING PROCESS SETTING UP.PHASE 6: PROTOTYPE VALIDATION AND HOMOLOGATION. These phases will be developed to the sand molding system in both vertical and horizontal technologies in Mogdal (Israel) and Furesa (Spain) with the technical support of the reseach and development center IK4-AZTERLAN.
Project ID: 
12 171
Start date: 
Project Duration: 
Project costs: 
1 060 000.00€
Technological Area: 
Iron and Steel, Steelworks
Market Area: 

Raising the productivity and competitiveness of European businesses through technology. Boosting national economies on the international market, and strengthening the basis for sustainable prosperity and employment.